Reinforcement plate flange junctions of composite components

Abstract

A composite component for a gas turbine engine includes a first composite component portion; a second composite component portion; and a metallic reinforcement plate connecting the first composite component portion and the second composite component portion, wherein the metallic reinforcement plate has a first arm at least partially overlapping the first composite component portion, and a second arm at least partially overlapping the second composite component portion.

We claim: 
     
         1 . A composite component for a gas turbine engine, comprising:
 a first composite component portion;   a second composite component portion; and   a metallic reinforcement plate connecting the first composite component portion and the second composite component portion, wherein the metallic reinforcement plate has a first arm at least partially overlapping the first composite component portion, and a second arm at least partially overlapping the second composite component portion.   
     
     
         2 . The composite component of  claim 1 , wherein the first arm and the second arm define an angle therebetween which is greater than 0 degrees and less than 180 degrees. 
     
     
         3 . The composite component of  claim 2 , wherein the first arm and the second arm have contact surfaces facing the first composite component portion and the second composite component portion, and the contact surfaces define the angle. 
     
     
         4 . The composite component of  claim 2 , wherein the angle is between 20 degrees and 160 degrees. 
     
     
         5 . The composite component of  claim 1 , wherein the first composite component portion and the second composite component portion have a thickness, and wherein the thickness is reduced where the first arm and the second arm overlap the first composite portion and the second composite portion. 
     
     
         6 . The composite component of  claim 1 , wherein the first composite component portion and the second composite component portion comprise PMC, MMC, CMC and combinations thereof. 
     
     
         7 . The composite component of  claim 1 , wherein at least one of the first arm and the second arm is bonded to at least one of the first composite component portion and the second composite component portion. 
     
     
         8 . The composite component of  claim 1 , wherein at least one of the first arm and the second arm is co-bonded to at least one of the first composite component portion and the second composite component portion. 
     
     
         9 . The composite component of  claim 1 , wherein at least one of the first arm and the second arm is mechanically fastened to at least one of the first composite component portion and the second composite component portion. 
     
     
         10 . The composite component of  claim 1 , wherein composite material of the first and second composite component portions and metallic material of the metallic reinforcement plate are selected to have substantially the same coefficient of thermal expansion. 
     
     
         11 . The composite component of  claim 1 , wherein metallic material of the metallic reinforcement plate is selected from the group consisting of Ti-based alloy, Co-based alloy, Ni-based alloy, aluminum and combinations thereof. 
     
     
         12 . The composite component of  claim 1 , wherein the metallic reinforcement plate further comprises a ceramic material. 
     
     
         13 . The composite component of  claim 1 , wherein the metallic material is selected from the group consisting of Ti-based alloy, Co-based alloy, Ni-based alloy and combinations thereof. 
     
     
         14 . The composite component of  claim 1 , wherein the component is selected from the group consisting of cases, ducts, rings, liners and combinations thereof. 
     
     
         15 . The composite component of  claim 1 , wherein the first composite component portion comprises a body portion of the component and the second composite component portion comprises a flange of the component. 
     
     
         16 . The composite component of  claim 1 , wherein the first composite component portion and the second composite component portion define at least two flanges, and wherein the metallic reinforcement plate has arms to extend along all of the at least two flanges. 
     
     
         17 . The composite component of  claim 16 , wherein the first composite component portion and the second composite component portion define a cylindrical surface with an axial flange at a meeting line between the first composite component portion and the second composite component portion, and a radial flange along an edge of each of the first composite component portion and the second composite component portion, and wherein the metallic reinforcement plate has a floor plate extending along a surface of the cylindrical surface, an axial reinforcement arm for reinforcing along the axial flange, and a radial arm for reinforcing the radial flange. 
     
     
         18 . A metallic reinforcement plate for composite components, comprising:
 a floor having a floor thickness;   a first flange reinforcement arm extending from the floor and having a first arm thickness;   a second flange reinforcement arm extending from the floor and intersecting the first flange reinforcement arm, the second flange reinforcement arm having a second arm thickness, wherein the first arm thickness and the second arm thickness have increased thickness at a point of intersection of the first flange reinforcement arm and the second flange reinforcement arm.   
     
     
         19 . The metallic reinforcement plate for composite components of  claim 18 , wherein the floor has an increased thickness at a point of intersection of the first flange reinforcement arm and the second flange reinforcement arm. 
     
     
         20 . A method for making a composite component, wherein the composite component comprises at least a first composite component portion and a second composite component portion, the method comprising the steps of:
 joining the first composite component portion to a metallic reinforcement plate, wherein the metallic reinforcement plate comprises at least a first arm and a second arm, by overlapping the first arm and the first composite component portion; and   joining the second composite component portion to the metallic reinforcement plate by overlapping the second arm and the second composite component portion.